EP0925264A1 - Procede et dispositif pour la production de plaques de materiau ceramique - Google Patents

Procede et dispositif pour la production de plaques de materiau ceramique

Info

Publication number
EP0925264A1
EP0925264A1 EP98920537A EP98920537A EP0925264A1 EP 0925264 A1 EP0925264 A1 EP 0925264A1 EP 98920537 A EP98920537 A EP 98920537A EP 98920537 A EP98920537 A EP 98920537A EP 0925264 A1 EP0925264 A1 EP 0925264A1
Authority
EP
European Patent Office
Prior art keywords
matenal
layer
mixture
die
sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP98920537A
Other languages
German (de)
English (en)
Inventor
Marcello Toncelli
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP0925264A1 publication Critical patent/EP0925264A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
    • B28B5/04—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping in moulds moved in succession past one or more shaping stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • B28B7/368—Absorbent linings

Definitions

  • the present invention relates to the manufacture of slabs of ceramic material and, more specifically, to an improvement in apparatus for the manufacture of such products.
  • European patent 378,275 describes a slab of ceramic material and a method for its manufacture which provides for the preparation of a ceramic mixture constituted by granulated material and by an inorganic binding phase having particular characteristics of composition; the granulated material also has specific particle-size parameters.
  • the mixture is formed into slabs by being spread on a forming support and a pressure, combined with a simultaneous vibratory motion, is applied to the mixture thus spread, which is kept under vacuum.
  • the raw slab is subjected to a first, drying step at a temperature below that at which ceramics are fired but nevertheless greater than 100°C and to a second, firing step in which the dried slab is brought to a temperature of the order of 1000-1300°C.
  • the layer of mixture deposited is then covered by a layer or sheet of paper permeable to water vapour and the whole thing is then transferred to the step for pressing under vacuum and simultaneous application of vibratory motion.
  • the raw slab thus formed is picked up by devices with suction cups and is transferred, whilst being kept in the same position and the same orientation, onto a support surface, preferably in the form of a metal mesh, after which the sheet of permeable paper is removed.
  • refractory slip a layer of refractory material (which is known in the art as a "refractory slip"), the composition of which generally consists of magnesium carbonate and a plastic clay which are mixed with water, is applied to its upper surface.
  • the raw slab After the application of the protective refractory layer, the raw slab is turned over in order to be introduced into the firing kiln where the protective paper, which at this stage constitutes the upper covering of the dried slab, is removed (by burning) whilst the lower surface of the slab which is in contact with the support on which the slab is transported or rests in the kiln (according to the type of kiln) is protected by the aforementioned layer of refractory material (the slip).
  • This layer may be removed by conventional techniques upon completion of the firing step, after which the slab goes on to conventional finishing operations (sizing, smoothing, polishing) if desired
  • the main object of the present mvention is to prevent these problems and disadvantages by improvements to be introduced in the apparatus and in the method of manufacture of the slabs defined above, without detriment to the properties, quality, or appearance of the resulting slabs
  • the present mvention provides for a method for the manufacture of slabs of ceramic material of the type identified above which is characterized in that the startmg mixture is deposited on ⁇ e forming support after a layer of mechanically resistant fabric, particularly felt, has been arranged on this support, a layer of release matenal, permeable to water vapour preferably paper, being placed on the felt and the layer of mixture disposed on the support thus prepared being covered with a sheet of a release material, such as rubber or another substantially elastomenc matenal, after which the step of pressing under vacuum with the simultaneous application of a vibratory motion of predetermined frequency and duration is earned out and, before the drying step and the subsequent firing step, the aforementioned rubber sheet is removed and the raw slab is transferred to the subsequent drying step by the gnpping of the front portion (with reference to the direction of movement of the support along the production line) of the felt carrying the raw slab by pincer means so as to transfer the assembly onto a gnd- ke support to be introduced into the drying oven
  • the apparatus according to the present invention which is of the type comprising means for prepa ⁇ ng the starting mixture of granulated matenal and binding phase, means for supplying and spreading a metered quantity of the mixture onto a support movable along the production line, means for the pressing under vacuum of the metered quantity of mixture spread on the support and the simultaneous application of a vibratory motion thereto, a drying zone, means situated downstream of the drying zone for applying a layer of refractory matenal for protecting the raw slab, and a zone for the firing of the raw slabs supported on the side covered by the layer of refractory matenal, is characte ⁇ zed in that it compnses means for supplying a layer of mechanically resistant fab ⁇ c, preferably a felt, and placing it in position on the movable support upstream of the position in which the starting mixture is supplied and spread, means for supplymg a layer of release matenal permeable to water vapour , preferably paper, and placing it in position on the layer of felt, means
  • Figure 1 is a general plan view of the apparatus according to the mvention
  • Figures 2A and 2B arc schematic side elevational views of a portion of the apparatus of the present mvention
  • Figures 3A and 3B are plan views of the portion of the apparatus of Figures 2A and 2B.
  • Figures 4, 5, 6, 7, 8, 9, and 10 are partial views showing m section the raw slabs in the successive stages of their formation and movement through the vanous stations of the apparatus, the sections relating to the positions indicated S4, S5, S6, S7, S8, S9, and S10 in Figures 2A and 2B, and
  • FIG 11 shows the detail of the apparatus identified by the oval in Figure 2B
  • Figures 4 to 10 show a support structure compnsing a framework 18 which supports for movement a conveyor belt 20 which may differ in the vanous portions of the apparatus
  • the conveyor is replaced b> a support surface made of heat-resistant matenal
  • the production lme starts with a station 14 which provides for the loading of a felt or cloth 16 in the portion 14A and provides for a sheet or layer of paper 22 permeable to water vapour to be placed on the felt 16 in the portion 14B, the conveyor belt 20 then enters the station 24 in which a mixture-supply and spreadmg mechamsm spreads on top of the sheet of permeable paper 22 a layer 26 of mixture of predetermined thickness, taken from the suppK duct or channel 12
  • the embodiment shown provides for a reinforcing mesh to be inserted and incorporated in the thickness of the final layer of mixture and the station 24 is therefore followed by a station 28 for loading a mesh 30 of a matenal compatible with the final slab and placing it in position on top of the layer of mixture 26
  • compatibdity is meant, in particular, that the shrinkage of the matenal constituting the reinforcing mesh should be substantially of the same order of magnitude as that of the mixture when it is subjected to the drying and firing steps
  • a second layer 32 of the same mixture is placed on top of the remforcmg mesh 30. forming the la ⁇ er 26 in the station 34
  • the upper surface of the mixture and thus of the layer 32 is covered and protected by a sheet of elastome ⁇ c release matenal such as, for example rubber, this sheet, identified b ⁇ the reference numeral 36, bemg applied in the station 38 As can be seen from Figure 8.
  • the rubber sheet 36 has dimensions such that its pe ⁇ phery overlaps the pe ⁇ phenes of the permeable paper sheet 22 and of the felt 16 which also project, so that the mixture which, m this case, is constituted by two layers 26 and 32 with the remforcmg mesh 30 interposed between them, is completely enclosed by a protective envelope which, however, is porous on the lower side (by virtue of the presence of both the felt and the permeable paper) allowing moisture also to come out of the lower side during the subsequent drying step
  • the mixture is then transferred to the pressing station 40 where it is subjected, under a pre-established vacuum, to a predetermined pressure and to the simultaneous effect of a vibratory motion, forming a raw slab which does not, however, yet have sufficient mechanical solidity to be handled without special measures
  • the rubber sheet is removed (station 42) and is returned to the application station 38 after suitable cleaning of residues of mixture
  • the raw slab which is now m the condition of Figure 10, is advanced to the station 44 where it is transfe ⁇ ed onto a different conveyor support, preferably constituted b a metal gnd
  • pincer means which can g ⁇ p the projecting front edge (in the direction of advance of the conveyor belt) of the felt 16 and of the permeable paper 22, so that the raw slab is slid forwards, together with the felt and the permeable paper, until it engages the new conve ⁇ or support constituted, in fact, by a metal gnd
  • the above-mentioned pincer means are shown in greater detail m Figure 1 1
  • these means are constituted substantially by a rectangular frame 70 which is formed by a senes of side members and cross members a ⁇ anged side by side and parallel to one another (see Figure 3B) and which is movable forwards and backwards relative to the fixed load-bearing structure on which it is mounted between a position for depositing a slab on the gnd and a position for gnppmg the felt where the slab is lying,
  • Figure 3B shows in broken outlme the shape of the portion of the frame arranged for gnppmg a slab amving in this latter position
  • the frame is moved by an electnc motor 71 acting on a shaft 72 at the ends of which there are respective pinions (not shown m the drawings) coupled with corresponding racks (also not shown graphically) mounted on the fixed load-bea ⁇ ng structure
  • the gnppmg action of the pmcer means is ensured by a lower hp 75 and an upper hp 76, of which the former is fixed to the frame 70 and the latter is movable relative thereto since it is fitted on the translating element 77 of an articulated- quadnlateral kinematic mechanism of which two rocker arms 78 articulated to the frame 70 also form part, in particular, the movement of the upper hp 76 is brought about by a senes of hydraulic cylinders 80 mounted on the frame and acting on the translating element 77
  • the pmcer means have released the felt and the permeable paper
  • the raw slab thus reaches the station 46 where it is advanced, together with the g ⁇ d-like support on which it is deposited, towards a drying oven 48 of conventional type well-known per se, in which it is subjected to the effect of heat, preferably in the form of a forced circulation of hot air, the time spent in the oven being such as to achieve a first mechanical solidification of the mixture which forms the raw slab so that it can
  • the slab still on the g ⁇ d-like support, is sent to the station 49 in which it is lifted up by a suction-cup system and transferred to a starting station 51 of the next portion of the conveyor 20, after this lifting, the g ⁇ d-like support and the felt disposed thereon can then be taken from the station 49 for re-use in the production cycle as desc ⁇ bed above
  • the slab then reaches the station 53 where a thin layer of refractory matenal (the aforementioned slip) is applied to it and is then d ⁇ ed m the next station 54, after this, the slab is turned over in the station 55, that is to say, as a result of this turning over, the layer of slip, solidified by drying, is disposed underneath the slab and m contact with the conveyor which moves it forwards At this point, it remains only to introduce the raw and d ⁇ ed slab resting on its face which is covered with and protected by the refractory slip, mto the firing lain 52, which is preferably of the tunnel type well- known per se, in which the firing of the mixture and its transformation into ceramic matenal is also combined with burning of the permeable paper which covers the upper surface of the raw slab After firing, the slab may be transferred to normal finishing operations such as smoothing, polishing, etc
  • components such as the rubber sheets, can be re-used as they are (after merely being cleaned of deb ⁇ s and residues of mixture) so that industrial production costs are also controlled and, in particular, limited, whilst the number of slabs to be rejected owing to damage resultmg from handling before the firing step is drastically reduced
  • the two stations 24 and 34 may be reduced to a single station for the deposition and spreadmg of the mixture when the slab does not have to contain a remforcmg mesh 30
  • the present mvention may be applied in a similar manner with suitable adjustments to processes and apparatus in which slabs are formed from mixtures which are subsequently subjected to drying and setting steps m which, up to now, the mixture generally had to be incorporated between two paper sheets for the pressing and subsequent operations, since it enables the raw slab to be handled without the hitherto unsolved problem of susceptibdity to damage.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Abstract

L'invention concerne un procédé de production de plaques de matériau céramique à partir d'un mélange formé par un matériau granulé et une phase de liaison inorganique dans lequel le mélange de départ est étalé sur un support constitué d'une toile ou d'un feutre résistant mécaniquement couvert d'une couche ou feuille de matériau de séparation perméable à la vapeur d'eau, tel que du papier. On couvre la couche de mélange d'une feuille protectrice de matériau de séparation, du caoutchouc de préférence, puis on forme la plaque en appliquant une pression de compactage sous vide ainsi qu'un mouvement vibratoire simultané. On enlève la feuille de caoutchouc de la plaque brute ainsi obtenue, qui est transférée avec un système de tenailles sur un support ou une grille en métal utilisée pour les étapes de séchage et de cuisson. On envoie alors la plaque vers un four de séchage après quoi, une fois la feuille de feutre retirée, on en recouvre la surface visible d'une couche de matériau réfractaire, on la retourne et on l'envoie dans le four de cuisson où le papier perméable est brûlé.
EP98920537A 1997-04-15 1998-04-11 Procede et dispositif pour la production de plaques de materiau ceramique Withdrawn EP0925264A1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IT97TV000042A IT1293176B1 (it) 1997-04-15 1997-04-15 Procedimento ed impianto per la fabbricazione di lastre in materiale ceramico.
ITTV970042 1997-04-15
PCT/EP1998/002258 WO1998046543A1 (fr) 1997-04-15 1998-04-11 Procede et dispositif pour la production de plaques de materiau ceramique

Publications (1)

Publication Number Publication Date
EP0925264A1 true EP0925264A1 (fr) 1999-06-30

Family

ID=11420130

Family Applications (1)

Application Number Title Priority Date Filing Date
EP98920537A Withdrawn EP0925264A1 (fr) 1997-04-15 1998-04-11 Procede et dispositif pour la production de plaques de materiau ceramique

Country Status (4)

Country Link
EP (1) EP0925264A1 (fr)
CA (1) CA2287283A1 (fr)
IT (1) IT1293176B1 (fr)
WO (1) WO1998046543A1 (fr)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1311858B1 (it) * 1999-09-03 2002-03-19 Marcello Toncelli Procedimento perfezionato per la produzione di lastre in materialeceramico
ITMO20030174A1 (it) * 2003-06-13 2004-12-14 Morandi S R L Off Metodo per la formatura di manufatti ceramici sostanzialmente
ITTV20070054A1 (it) 2007-03-28 2008-09-29 Luca Toncelli Procedimento per la fabbricazione di lastre in materiale ceramico
ITTV20070126A1 (it) 2007-07-16 2009-01-17 Luca Toncelli Procedimento ed apparecchiatura per la fabbricazione di lastre ad effet-to venato
IT1393456B1 (it) 2009-03-10 2012-04-20 Toncelli Apparecchiatura e metodo per la fabbricazione di lastre ad effetto venato
IT201800020920A1 (it) 2018-12-21 2020-06-21 Luca Toncelli Metodo per la produzione di manufatti in lastra a partire da un impasto base, fritta vetrosa per la realizzazione dell’impasto base e manufatto in lastra così ottenuto
IT201800020944A1 (it) 2018-12-21 2020-06-21 Luca Toncelli Metodo per la produzione di manufatti colorati in lastra vetroceramica a partire da un impasto base, fritta vetrosa per la realizzazione dell’impasto base e manufatto colorato in lastra vetroceramica così ottenuto

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4908217A (en) * 1985-04-18 1990-03-13 Robert Abraham Limited Apparatus for making tiles or slabs
FR2709486A1 (fr) * 1993-09-02 1995-03-10 Programme 3 Patent Holdings Céramiques conductrices des ions.
JP2932911B2 (ja) * 1993-11-18 1999-08-09 株式会社村田製作所 グリーンシート成形用キャリヤーフイルム
JP2561221B2 (ja) * 1994-03-07 1996-12-04 株式会社麗光 セラミックシート製造用離型性フイルム
JP3685275B2 (ja) * 1996-06-25 2005-08-17 東洋紡績株式会社 離型フィルム

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO9846543A1 *

Also Published As

Publication number Publication date
ITTV970042A0 (it) 1997-04-15
ITTV970042A1 (it) 1998-10-15
CA2287283A1 (fr) 1998-10-22
WO1998046543A1 (fr) 1998-10-22
IT1293176B1 (it) 1999-02-12

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